Modular flooring substrate system and element

ABSTRACT

A modular substrate system for use in the support of a flooring surface including a plurality of elongate substrate members which can be rapidly assembled to provide a semi-rigid support surface for a floor. Various flooring elements can be adhered to the semi-rigid support surface using an adhesive to, in cooperation with the modular substrate system, provide an enhanced composite rigidity to the assembled floor. The substrate member itself includes an upper surface, side surfaces, and lateral flange portions, the lateral flange portions of the substrate members maintain adjacent substrate members in parallel spaced apart relationship to each other defining substrate channels therebetween. The substrate channels strengthen the assembled modular substrate system and provide routes of egress for water from below the flooring surface disposed thereon.

FIELD OF THE INVENTION

The present invention relates in general to flooring and decking/patiosystems, and more specifically, relates to a modular substrate systemfor use in the support, of a floor surface. Various flooring elementscan be adhered to the semi-rigid support surface to, in cooperation withthe modular substrate system, provide an enhanced composite rigidity tothe assembled floor incorporating the modular substrate system.

DESCRIPTION OF RELATED ART

In the construction of decking and floors a common approach is to builda wooden or metal frame upon which upon some form of decking material isthen placed to provide a suitable surface upon for furnishings or thelike to be placed, as well as which can be occupied by people. In somecases the decking surface can consist of wooden or composite planksattached to the underlying frame. In these cases, the planks areattached such that there is a small space between each plank to allowfor expansion, and for water to be shed from the top surface of thedeck.

A common problem with this type of decking system is that the area underthe deck is un-protected from moisture, and so the support structure istypically exposed to the elements an subject to degradation over time asa result. Where wooden joists are used, they can when contacted withwater below any waterproof treatment or membrane decay. If a metalsubstrate surface is used, with screws placed therethrough etc., oftentimes that will rust and the rusting of the substrate can again lead toa structural destabilization of the overall installation as well aspotentially ruining the visible appearance of the product if the rustbleeds through. Wooden and even composite materials must be maintainedover time in order to preserve both the structural integrity of the deckor patio, as well as to maintain aesthetic appearance. If it werepossible to create a substrate for use underneath the deck or otherflooring installation which was manufactured of materials that wereresistant to most types of decay this would represent an enhancementover current available products.

In addition to prior art problems with the ingress of water below anattached flooring surface into the substrate in a floor installation, itwould also be desirable to provide a system for the rapid deployment ofa semi-rigid flooring substrate in a minimal amount of material andsteps, to speed the overall assembly of decks or other floors. Forexample where a wooden joist structure is created, significant time isoften required to cut and assemble the joist work and substrata beneathsuch an installation. Different types of brackets and other systems havebeen created to ease the creation to a degree the assembly of a flooringsubstrate, but if it were possible to address the issue of structuralintegrity and water egress from the substructure of a deck or floor witha subassembly that was rapidly and simply assembled this would also beconsidered desireable.

Prior art methods of substrates and support for flooring surfaces haveincluded the use of flexible surfaces such as thin or metal, plywood orthe like, which are either too flexible, resulting in cracking or thepossibility of cracking of the overlying floor surface, or which requirethe addition of a concrete layer or the like to provide additionalrigidity. Provision of a method and apparatus for the construction of amodular substrate which would allow for rapid deployment of a substrateof reasonable rigidity would be attractive from a commercialperspective.

Metal is often seen as a desireable material for construction due to itsfluid resistant characteristics (dependent upon choice of material andfastening system). One of the issues with a metal surface of significantsize however is often that it is too flexible for a flooring or deckingpurpose. If the substrate of a deck is too flexible, it is more likelythat the flooring overlay or surface will crack or otherwise be damagedwhen the substrate flexes under weight load. As such, it is desired toprovide a substructure assembly that is at least semi-rigid and wouldnot flex so much as to make it ineffective as a supporting substrate fora deck or floor. If it were possible to create a substrate for adhesiveattachment of flooring elements which enhance the ability of water toexit from beneath the flooring surface and had maximized rigidity, toprovide maximum support to the overlying flooring surface it is alsobelieved that this would be well received.

BRIEF SUMMARY OF THE INVENTION

The present disclosure describes components and methods of manufactureand installation of said components to provide a modular substratesystem. The decking system provides a number of advantages over priormethods and components in that the components are simple to manufactureand assemble into a finished decking system. The modular substratesystem described herein provides for the use of rigid or semi-rigiddecking surface materials arranged in such a way that the componentscooperatively provide an effective degree of flexibility to the systemwhile avoiding the over-flex of the substrate which would result in thecracking or disruption of the flooring surface or membrane.

The modular substrate system of the present invention is made for use inthe support of a flooring surface. The floor surface might comprise asingle membrane, or a multi-component diaphragm. Both such approachesare contemplated within the scope hereof. The substructure is furtherdesigned to permit ingress of air and egress of water such that thegrowth of mold or mildew, or damage to supporting structures by water iseffectively prevented.

In some embodiments, the modular substrate system may comprise a groupof elongate substrate members configured to cooperatively form asubstrate mounting surface for the adhesive attachment of flooringelements thereto.

The modular substrate system is manufactured of metal which minimizesthe likelihood of water-based decay and provides sufficient strength andworkability to be advantageous as a material of manufacture. Adhesive isthe likely desireable means of attachment of the flooring surface, tomaintain the integrity of the substrate mounting surface as well as toachieve the flexible rigidity desired in terms of the cooperative actionof the flooring surface and the modular substrate system under weightload.

The completed modular substrate system comprises a plurality of elongatesubstrate members which align themselves with each other by cooperationof aspects thereof. Once the plurality of elongate substrate members areproperly aligned to complete the modular substrate system, they can beattached to each other, and the top of the assembled modular substratesystem comprises the substrate mounting surface.

It is contemplated that in many embodiments the substrate member willeffectively comprise a U-shaped member which will be inverted ininstallation. The substrate member may include a substantially flatupper surface, side surfaces meeting the upper surface in upper edges,and lateral flange portions at the distal ends of the side surfaces. Thelateral flange portions are the portions of the substrate member whichwill cooperate with like components of adjacent substrate members tomaintain them in properly spaced relationship in the assembly of themodular substrate system.

In some embodiments, each substrate member is substantially rigid alonga longitudinal axis, but is torsionally flexible around the longitudinalaxis; each lateral flange portion of each substrate member capable ofholding the substrate member when placed in parallel alignment with anadjacent substrate member such that a substrate channel is definedtherebetween; and/or whereby when the modular substrate system isassembled the upper surfaces of the substrate members.

In some embodiments, when the modular substrate system is assembled theupper surfaces of the substrate members may comprise the substratemounting surface and substrate channels run from one edge to the otherof the substrate mounting surface along the upper edges of the substratemembers. In addition to providing channels for water to exit from thesubstructure, the substrate channels also effectively act asstrengthening joists or corrugations within the completed assembly ofthe modular substrate system, which provide added strength and minimizethe flexibility of the modular substrate system.

In some embodiments, the lateral flange portions of a substrate memberare configured to engage lateral flange portions of adjacent substratemembers. The lateral flange portions, at the distal ends of the sidesurfaces of the substrate member, might comprise a flange extendingoutwards in a plane substantially parallel to the plane of the uppersurface of the substrate member, optionally with a retaining tab at theend thereof to provide a system which can most easily and completely berapidly assembled, and which will best strengthen the overall modularsubstrate system while maintaining the parallel and spaced apartrelationship of adjacent substrate members during assembly or completionof the modular substrate system.

In some embodiments; the modular substrate system is installed on apre-existing rigid surface. In other cases, a supporting frame might beused beneath the plurality of substrate members to further support, orraise the height, of the finished modular substrate system. In someembodiments, the supporting frame may include risers to raise themodular substrate system above the rigid surface.

In addition to the modular substrate system of the present invention,there is also disclosed a substrate member for use in construction of amodular substrate system for use in support of a floor surface. Thesubstrate member comprises an elongate structure that is substantiallyrigid along a longitudinal axis, but is torsionally flexible around thelongitudinal axis; and has a substantially flat upper surface, opposingside surfaces meeting the upper surface in upper edges, and lateralflange portions at the distal ends of the side surfaces. The lateralflange portions will engage a surface onto which installation of thefloor surface is desired; and are capable of holding said substratemember when placed and engaged in parallel alignment with an adjacentsubstrate member such that a substrate channel is defined therebetween.The lateral flange portions can further comprise engagement tabs at theends thereof, to fixedly engage the lateral flange portions of adjacentsubstrate members.

Many different cross-sectional profiles can be envisioned for thesubstrate member, including a substantially U-shaped crosssection. Thesubstrate member disclosed can be used in the assembly of a modularsubstrate system such as that outlined herein.

Also disclosed is a method of constructing a modular substrate systemfor use in support of a floor surface, said modular substrate systemcomprising a plurality of elongate substrate members configured tocooperatively form a substrate mounting surface for the adhesiveattachment of flooring elements thereto, each of the substrate memberscomprising an elongate U-shaped member having a substantially flat uppersurface, side surfaces meeting the upper surface in upper edges, andlateral flange portions at the distal ends of the side surfaces, andbeing substantially rigid along a longitudinal axis, but torsionallyflexible around the longitudinal axis; and the lateral flange portionsof substrate members maintaining adjacent substrate members in parallelspaced apart relationship to each other defining substrate channelstherebetween, said method comprising aligning the desired plurality ofelongate substrate members parallel to each other by alignment of thelateral flange portions thereof; and attaching the aligned substratemembers to each other. When the modular substrate system is assembledthe upper surfaces of the substrate members comprise the substratemounting surface and the substrate channels run from one edge to theother of the substrate mounting surface along the upper edges of thesubstrate members.

In the method, the lateral flange portions of a substrate member areconfigured to engage lateral flange portions of adjacent substratemembers.

In some cases the method might be used to construct a modular substratesystem on a pre-existing rigid surface, versus in others where asupporting frame was the be used beneath the substrate members themethod might also include the installation of said supporting frame inadvance of placement of the substrate members thereon.

In assembly of a modular substrate system in accordance with the presentinvention, the substrate members can be cut and shaped to accommodatethe general shape of the installation area, as can any supporting framebe manufactured to the proper height and size as well as potentiallyallowing for accommodation of surface irregularities at the point ofinstallation.

BRIEF DESCRIPTION OF THE DRAWINGS

To easily identify the discussion of any particular element or act, themost significant digit or digits in a reference number refer to thefigure number in which that element is first introduced.

FIG. 1 is a perspective view of an embodiment of a substrate member ofthe present disclosure.

FIG. 2 is a perspective view of an embodiment of a partially assembledsubstrate mounting surface, secured to a supporting frame. substratemounting surface

FIG. 3 is a view of an embodiment of adjacent substrate members andshowing the nesting of lateral flange portions of the adjacent members,and a means of securing to a supporting frame.

FIG. 4 is a perspective view of an embodiment of a partially assembledsystem according to the present disclosure, depicting a supportingframe, substrate members forming a substrate mounting surface, andsurface elements installed on the substrate mounting surface.

FIG. 5 is a end on view of substrate members onto which surface elementshave been placed directly without providing for an intervening spacebetween the substrate members and surface elements.

FIG. 6 is an embodiment shown in edge on view, in which the surfaceelements and substrate members are separated by flexible cushions intowhich the surface elements are mounted.

DETAILED DESCRIPTION

As discussed above, most decking systems have limitations due to theirdesign. In simple decking systems, the decking material is typicallyplanks or slats that are installed with spaces between each slat/plankmember. This design allows for the shedding of water, and permitsairflow under the decking such that water does not accumulate and causedamage over time either directly, or by stimulating the growth of moldand mildew. In order to overcome this limitation and provide a moreuniform surface, a variety of approaches including multilayer deckingsystems have been developed. However, these systems suffer from thelimitation that they are more complicated to install, have morecomponents, and thus are more expensive to manufacture, install andmaintain. The present modular substrate system overcomes the limitationspresented by prior art systems.

A modular substrate system in accordance with one embodiment of thepresent invention is shown in FIG. 1. In some embodiments, for exampleas depicted in FIG. 1, a component of the system comprises a substratemember 10. In some embodiments, the substrate member 10 can be formedfrom a piece of sheet metal such that it forms a U-shape structure. Theformed substrate member 10 preferably has an substantially flat uppersurface 12, side surfaces 14, and lateral flange portions 16. Thelateral flange portions 16 can also be formed with a hole through whicha fastener can be passed in order to secure each substrate member 10 toan underlying supporting frame 20, and to an adjacent substrate member10.

Preferably a substrate member 10 can be fashioned from metal stock, suchas that used in the making of the metal version of 2×4 members used inbuilding construction. The U-shape of the substrate member 10 providesseveral structural and functional advantages. First, the U-shapeprovides for significant rigidity along the longitudinal axis of themember, such that it will be relatively resistant to bending—as a resultof the multiple corrugations in its structure. Thus, a substrate member10 is capable of supporting a significant weight load without collapsingor failing.

Further, as a result of the open U-shape, each substrate member 10 willbe capable of some torsional rotation around the longitudinal axis. Thisprovides two advantages. First, the ability to rotate one end of thesubstrate member 10 relative to the other means that the underlyingsupporting frame 20 does not have to be perfectly aligned in order toinstall a substrate member 10 spanning different parts of the supportingframe 20. In addition, this torsional flexibility provides for theability of the substrate member 10 to adapt to small changes in theshape of the finished deck or flooring system that may occur over time.Such changes can occur as a result of movement of the underlying surfaceupon which the system is mounted, such as may occur with groundmovement, or as a result of regular changes due to thermal expansion andcontraction of the materials of which the decking system is comprised.As will be seen from the description below, the nature of the surfaceelements that are used to cover the substrate members, 10 and the way inwhich they are mounted and sealed, also provides for a membrane orsurface that behaves as a rigid decking system, but which is able toflex without disrupting the integrity of the overall system.

In constructing the modular substrate system of the present invention,and as shown in FIG. 2, a plurality of elongate substrate members 10 aresecured to an underlying supporting frame 20. The supporting frame 20can be fashioned from any suitable building material including wood,composite or metal beams. The supporting frame 20 will in some cases bemounted on risers 22, that are in turn mounted on the ground, or someother type of supporting surface, such as concrete or a preparedaggregate. In some cases, it may be preferable to place the supportingframe 20 directly on the ground or other surface, without the need forrisers 22. The particular type of installation of the supporting frame20 will depend on the particular characteristics of the location wherethe modular substrate system is to be installed.

In still other embodiments, it is possible to place the modularsubstrate system comprising a plurality of elongate substrate members 10secured to each other directly upon a surface. The surface on which thesystem is placed can be the ground, a prepared site such as concrete orgravel fill, or on other materials such as foam sheets or othersemi-rigid material. The modular substrate system is in this regardquite adaptable and suitable for use in a variety of locations.Moreover, because of the ease of assembly, the system is potentiallyeven usable as a temporary substrate system that can be assembled, thendisassembled for use at a different location.

As also shown in FIG. 2 a plurality of elongate substrate members 10 canbe placed adjacent to each other to span the distance between opposingportions of a supporting frame 20, where such a supporting frame 20 isused. Conveniently, the U-shape of the substrate member 10 and lateralflange portions 16 cooperate to maintain adjacent substrate members 10in a parallel, spaced-apart relationship, defining substrate channels 21between adjacent substrate members 10. These substrate channels 21 serveto let water run out from the system, and to admit air, circulation inorder to avoid the development of condensation, and drying underneaththe finished surface that is eventually supported by the substratesystem. This provides the advantage of protecting the substrate systemfrom damage due to mold, mildew and corrosion from standing water. Thesubstrate channels also effectively act as strengthening joists withinthe structure of the modular substrate system.

FIG. 3 provides a more detailed view of the relationship between thesupporting frame 20 and adjacent substrate members 10. As can be seen,each substrate member 10 comprises an upper surface 12, side surfaces14, and lateral flange portions 16. The lateral flange portions 16 areshaped such that the lateral flange portion 16 of one substrate member10 conveniently nests into the lateral flange portion 16 of an adjacentsubstrate member 10. Once nested in this fashion, the substrate members10 can then be secured to the underlying supporting frame 20 with afastener 18.

In some embodiments, the lateral flange portions 16 and distal ends ofthe side surfaces 14 of the substrate members 10 will engage a surfaceonto which installation of a horizontal floor surface is desired, forexample, and as shown, an underlying supporting frame 20. Fasteners caninclude any suitable fastener known to those of skill in the art, andthe choice of fastener is not meant to be limiting to the scope of theinvention. As can also be appreciated from FIG. 3, the side surfaces 14are angled away from the perpendicular with respect to the upper surface12 of each substrate member 10, thus creating slightly trapezoidalshaped substrate channels 21 between adjacent substrate members in someembodiments.

FIG. 4 depicts a partially completed modular substrate system,manufactured and assembled as described herein. As can be appreciated,the supporting frame 20 is completely covered by a plurality of elongatesubstrate members 10, arranged substantially parallel to each other, andsecured to the supporting frame 20 as shown in FIG. 3 and FIG. 4. Theplurality of elongate substrate members 10 thus act cooperatively toprovide a substrate mounting surface onto which surface elements 40 canbe mounted. In the depicted embodiment, each surface element is depictedas a square tile. Other type of elements are suitable for use in thesystem, and other shapes are contemplated as well. As an example, foraesthetic reasons, a triangular shaped surface element might be desired.Because of the ease of assembly and adaptability of the present system,a wide variety of shapes, and types of material can be used in thesurface elements. Tiles, or surfacing elements of many different typesof material, can be used—including wood, plastic, ceramic, cement,vinyl, composite lumber to name a few.

FIG. 5 depicts an edge-on view of a portion of the modular substratesystem. In this case, three adjacent substrate members 10 are depictedmounted on an underlying supporting frame 20. A series of adjacentsurface elements 40 are also shown, installed on top of the substratestructure formed by the substrate members 10. The shape of the edgesresults in the formation of a void 44, which in the finished deckingproduct is filled with a flexible adhesive joint material 46. This jointmaterial 46 serves a number of functions. First, when complete, thecombination of surface elements and joint material operate such that thefinished upper surface of the modular system functions as a unitarydiaphragm. Moreover, this diaphragm is substantially waterproof,preventing moisture from getting underneath the finished surface, andthus substantially avoiding the risk of water damage to the underlyingsubstrate components of the system.

FIG. 6 depicts another embodiment wherein the surface elements areseparated from the substrate members 10 by flexible adhesive cushions60. The cushions 60 operate to support surface elements 40 above thesubstrate members 10, thereby creating an air space 61 of defined withbetween the surface elements 40 and the substrate members 10. The airspace 61 functions to admit airflow between these layers in order toavoid accumulation of moisture that might otherwise lead to water damagedirectly, or as a result of the growth of mold and/or mildew. Preferablythe cushions 60 are formed from an elastomeric material such that theyare flexible and can deform under conditions of loading to permit thefinished flooring system to flex resiliently while in use. Any type of afastening approach for surface elements which allowed for attachment ofa flooring surface while maintaining the integrity of the substratemounting surface and the semi-rigid character of the modular substratesystem are contemplated within the scope hereof.

In some embodiments, the modular substrate system can be installed on apre-existing rigid surface, for example, a supporting frame 20 asdepicted in FIG. 2. Such a supporting frame 20 can be formed in a mannerknown to those of skill in the art. In some cases it will be preferableto use a metal supporting frame 20 for reasons of strength anddurability. In other cases, it may be desirable to produce a supportingframe 20 from wood or other materials. In installing the present systemthe supporting frame 20 can be placed directly on a prepared surfacesuch as the ground, or an aggregate base. In other cases it will beconvenient to mount the supporting frame 20 on supporting structures toraise the deck above ground level. The particular types and design ofsupporting structure on which the supporting frame 20 is mounted willdepend on the nature of the building site, whether the deck is at ornear ground level or elevated, and the requirements of local buildingcodes.

Once the supporting frame 20 is in place, individual substrate members10 are secured to the frame as shown above. Conveniently, each substratemember 10 can be secured to the supporting frame 20 with typicalfasteners such as metal screws. As depicted above, each substrate member10 is nested alongside an adjacent substrate member 10 by virtue of thelateral flange portions 16 present on each substrate member 10. Theselateral flange portions 16 will run substantially the entire length ofthe substrate member 10, thus providing maximal integrity of thesubstrate mounting surface formed. Further, because of the U-shape ofeach substrate member 10, collectively the substrate mounting surfaceformed by a plurality of elongate substrate members 10 will includeregularly spaced substrate channels that admit air, and allow for theegress of any water that may accumulate under the finished surface ofthe decking.

Once the substrate members 10 are in place and attached, theconstruction of the modular substrate system is complete. A flooringlayer can then be attached—for example by placing adhesive on eachsubstrate member 10 and attaching flooring elements thereto. Asdescribed, support pylons are preferably formed from an elastomericmaterial that also has adhesive properties. Alternatively, it ispossible to manufacture the substrate members with support pylonsalready installed, in order to save the decking installer effort duringthe building of a modular substrate system. Once the surface elementsare positioned, an installer then fills the void between each surfaceelement with a flexible adhesive joint material. This material ispreferably also an elastomeric material that is elastically deformable.Once all the voids have been filled with the joint material, the upperfinished surface of the deck will function as an unitary, substantiallywaterproof, membrane, that covers the underlying substrate members andsupporting frame. The resilient nature of the joint material alsopermits a small amount of movement of each surface element relative toits neighboring elements, thus allowing the decking surface to respondto variations in temperature, or position of the underlying supportingstructure, while preventing disruption of the membrane.

One advantage of the present system is that each of the elementscooperate to provide a resilient and flexible decking surface thatavoids problems with cracking of surface elements as can occur when hardmaterials such as tile or stone are mounted directly on a rigidsubstrate.

It will be recognized that the specific materials used in constructingthe various components of the system described herein, are notconsidered to be limiting to the scope of the invention. Those of skillin the art will readily recognize and be able to select materials andcomponents that will accomplish the objectives of the invention withoutrequiring any inventive skill.

It should also be apparent to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the scope of theappended claims. Moreover, in interpreting both the specification andthe claims, all terms should be interpreted in the broadest possiblemanner consistent with the context. In particular, the terms “comprises”and “comprising” should be interpreted as referring to elements,components, or steps in a non-exclusive manner, indicating that thereferenced elements, components, or steps may be present, or utilized,or combined with other elements, components, or steps that are notexpressly referenced.

1. A modular flooring system, comprising: a substrate system comprisinga plurality of adjacent and parallel elongate substrate members eachhaving a substantially flat upper surface, side surfaces meeting theupper surface in upper edges, and lateral flange portions at the distalends of the side surfaces, each substrate member being substantiallyrigid along a longitudinal axis and torsionally flexible around thelongitudinal axis, the flat upper surfaces of the substrate membersforming an upwardly-facing substrate mounting surface; and a floorsurface, a bottom of which is adhesively attached to the substratemounting surface; wherein the substrate system is created by parallelalignment of the substrate members such that each pair of adjacentsubstrate members is retained in position by interaction of the lateralflange portions of the adjacent side surfaces of the pair, creating asubstrate channel therebetween which remains open to the bottom of thefloor surface; and wherein the adhesive attachment of the bottom of thefloor surface to the substrate mounting surface creates a space betweenthe floor surface and the substrate system allowing for movement ofwater across the substrate mounting surface and into the substratechannels such that water between the floor surface and the substratemounting surface has unimpeded flow access to the substrate channels toexit from one edge to the other of the substrate mounting surface. 2.The modular flooring system of claim 1, wherein each substrate memberforms a U-shaped structure.
 3. The modular flooring system of claim 1,wherein the lateral flange portions of a substrate member are configuredto engage lateral flange portions of adjacent substrate members.
 4. Themodular flooring system of claim 1, wherein the adhesive attachment ofthe floor surface to the substrate mounting surface comprises aplurality of setting adhesive mounts which will support the floorsurface to create the space between the floor surface and the substratesystem. 5-17. (canceled)
 18. A method of constructing a modular flooringsystem comprising: (a) a substrate system comprised of a plurality ofadjacent and parallel elongate substrate members each having asubstantially flat upper surface, side surfaces meeting the uppersurface in upper edges, and lateral flange portions at the distal endsof the side surfaces, each substrate member being substantially rigidalong a longitudinal axis and torsionally flexible around thelongitudinal axis, the flat upper surfaces of the substrate membersforming an upward-facing substrate mounting surface; and (b) a floorsurface having a bottom adhesively attached to the substrate mountingsurface; the method comprising i) aligning the plurality of elongatesubstrate members by parallel alignment of the lateral flange portionsof adjacent pairs thereof such that each pair of adjacent substratemembers is retained in position by interaction of the lateral flangeportions of the adjacent side surfaces of the pair, creating a substratechannel therebetween which remains open to the lower surface of thefloor surface and in aggregate defining the substrate system; ii)attaching the aligned substrate members to each other; and iii)adhesively attaching the bottom of the floor surface to the substratemounting surface such that a space is created between the floor surfaceand the substrate system allowing for movement of water across thesubstrate mounting surface and into the substrate channels; wherein eachsubstrate channel remains open to the lower surface of the floor surfaceso that water between the floor surface and the substrate mountingsurface has unimpeded flow access across the substrate mounting surfaceto the substrate channels to exit from one edge to the other of thesubstrate mounting surface.